Production of block polymer adhesives

ABSTRACT

Method for preparing adhesive compositions subjecting a mixture of block polymer and other adhesive constituents e.g., resin(s) and oil(s) to shearing and smearing in an emulsifier disperser.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of application Ser. No.07/996,830, filed Dec. 23, 1992 the disclosure of which is herebyincorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the production of adhesives containing blockpolymers and more particularly to block polymer pressure sensitiveadhesives (PSA) of various compositions. Many such adhesive compositionsand specifically PSA compositions are well known in the art. Moreparticularly, the invention relates to an improved method for theproduction of these adhesives.

2. Description of the Related Art

Since this invention is of more importance presently to PSA's, thefollowing descriptions will refer primarily to such adhesivecompositions for purposes of exemplifications of the method of theinvention.

Pressure sensitive adhesives (PSA) and other adhesive compositionsmaking use of block copolymers include both linear and radial types.Generally, such block copolymers may be represented schematically as:##STR1## wherein A blocks may comprise for example, polymerizedvinyl-substituted aromatic monomers and the B may blocks may comprisefor example, polymerized dienes having 4-12 carbon atoms or otherelastomeric or rubbery polymeric component(s). In the radial polymers apolyfunctional coupling agent is included and these are well known, forexample, see U.S. Pat. No. 3,639,521. In the case of PSA's, the A blockspreferably comprise polymerized styrene and the B blocks preferablycomprise polymerized butadiene isoprene, or mixtures thereof orhydrogenated versions thereof. Such copolymers typically have amolecular weight in the range of about 70,000-140,000 and have about 12to 35 wt-% styrene. Such block copolymers are available from ShellChemical Company, Enichem, Fina and Firestone and others. A common blockpolymer of this type is KRATON 1102, available from Shell and isreferred to herein by way of exemplification of the invention.

In addition to the block polymer constituent(s), PSA compositions willinclude tackifying resin(s), plasticizing oils and sometimes otheroptional ingredients, as is well known in the PSA art. Other blockpolymer adhesive compositions may include waxes, non-tacky resins and soforth.

A wide variety of PSA compositions are known and used in the art asevidenced for example by U.S. Pat. No. 5,024,667 and U.S. Pat. No.5,037,411 all compositions of which may be produced by the method ofthis invention. Likewise, a wide variety of tackifiers are known as arewide varieties of the plasticizer oils. For example, typical tackifyingresins include rosin, tall oil, rosin ester resins, natural andsynthetic terpenes and various aromatics. Plasticizer oils are primarilyhydrocarbon oils, typically paraffinic or naphthenic in character.However, other plasticizers may be used.

Most preferred for use herein, when PSA compositions are involved, arethe block copolymers wherein the A block or non-elastomeric block isstyrene and the elastomeric or B block is butadiene. Typically thelatter is present at levels of about 50 to 80 wt% although this willvary and is not critical. The method maybe practiced with any PSAcompositions and any other block polymer adhesive compositions. Blockpolymers of this specific type and composition are commerciallyavailable from Shell Chemical Company under the tradename KRATON 1102(about 70 parts butadiene and 30 parts styrene) among others. Othermanufacturers of block polymers for adhesives are well known. Blends ofthese high molecular weight copolymers with compatible low molecularweight block copolymers may also be employed. All such foregoingpolymeric compositions are referred to herein as "block polymer(s)" ingeneral and collectively.

The traditional method of preparing block polymer adhesives is to addresin and oil to a jacketed tank equipped with a standard verticalagitator. This mixture is heated to about 300° F. and beads of blockpolymer are added. The temperature is maintained between about 300° to350° F. with continued agitation. The adhesive is complete when theblock polymer is completely blended into the resin/oil mixture. The timerequired for complete blending is usually 6 hours to 24 hours, dependingon the degree of agitation. Block polymer beads disperse very slowlywithout a shearing and smearing action. Such long times at temperaturecan cause degradation of the polymer.

The commonly preferred and commercially practiced prior art method forproducing block polymer PSA compositions involves the working in shearof the block polymer. This is usually initiated by adding preformedcommercially available beads of the selected polymer composition toconventional thermoplastic polymer processing equipment capable ofproviding sufficiently high shear to blend the polymer by working it toa taffy-like melt. Small amounts of tackifier resin and oil may be addedinitially to facilitate the working. The block polymer is typicallyavailable commercially in a bead-like form and a variety of compositionsfor this purpose are available from many sources.

In the prior art, after working the polymer, (typically 30 minutes - 2hours or so), to achieve the taffy-like melt condition the main additiveamounts of resin, oil and/or any other ingredients are added. The resinis preferably heated prior to being added to the melt. The resultantliquid composition is passed from the processing equipment to a holdingtank or the like and then to the final container such as a drum, pillowbox, or the like in which it is ultimately sold, where it is allowed tocool and solidify.

The processing equipment used for this purpose is extremely expensive inexcess of hundreds of thousands of dollars, and is very high powerconsumptive in operation. Typically it includes such equipment as screwextruders, Mixtruders, Sigma Blademixers or the like.

More detailed information on presently practiced production methods forPSA is described in the following articles:

The article "Machinery and Equipment" of Plastics Compounding Redbook or1987/88, is a compilation of information regarding compounding and sizereduction equipment including lab and production scale blendingapparatus. The articles "Liquid Resin Injection System for ContinuousMixing of HMPSA" and "Extruder Performance Over Broad Meld Index Ranges"discuss blending materials having different viscosity profiles.

The article "Advance in Production and Coating Technology for Hot MeltPressure Sensitive Adhesives-Multiruder System" discusses the multirudersystem of premixer, multiruder and coater and is used for continuousproduction and coating of hot melt pressure sensitive adhesives forlabels and tapes.

The article "Continuous Compounding of Hot Melt Adhesives" discussescontinuously operating blending systems capable of blending hot meltadhesives with reduced heat history. Such compounding systems involveextrusion processing.

The article "Technical Aspects for Extrusion Compounding of Hot MeltAdhesives" discusses continuous processing systems for the manufactureof hot melt and pressure sensitive adhesive formulations using batch andtwin screw manufacturing methods.

The article "Twin Screw Extruder Process of Adhesive" discussescontinuous processing hot melt adhesive compounding with block polymerformulations using multi-stage feeding of oil resins, additives and basepolymer.

The article "Continuous Production of Hot Melt Adhesives Aspects ofQuality and Costing" discusses basic processing possibilities forproducing hot melts continuously involving working from a premix anddeals with four basic continuous processes. The disclosure involvesmulti-stage addition, pelletizing, coating, etc. Equipment for suchmanufacture is shown in the brochures of Welding Engineers, Inc., EaganManufacturing Company, Buss-Kneader, Warner and Pfleiderer, Conair andBlack Clausen.

In accordance with this invention a new and improved method of preparingadhesive compositions is provided. The new method minimizes the cost ofprocess equipment and minimizes heat degradation of the block polymer.Most importantly the process time involving the polymer is a matter ofan hour or even merely minutes rather than hours. This is important withrespect to reducing the heat and shear to which the polymer issubjected. Additionally, the method consumes less electrical energy andutilizes lower horsepower motors than the prior art.

SUMMARY OF THE INVENTION

To produce adhesives according to this invention, one charges theconstituents to a mixing vessel. All or some of these constituents maybe used initially. The sequence of mixing these constituents is notcritical and may vary. This mixture is then mechanically emulsified ordispersed to shear and smear the polymer over a relatively short timeinterval. Preferably, a melt is prepared and the block polymer, in aparticulate form preferably, is added to the melt and held for a periodof time to allow for softening of the polymer. Preferably the melt ismixed or agitated at this time.

Most preferably, to produce PSA compositions according to the invention,one charges the oil and resin additives to a vessel in which mixing maybe accomplished. The charge mixture is heated to a suitable temperature,such as about 220°-300° F., then the block polymer, in bead formpreferably or any other particulate form, is added to the heated chargemixture of resin/oil and the polymer particles are mixed therewith for afew minutes to soften them and insure that the charge is substantiallyuniform.

The resultant hot mixture with softened polymer is then pumped,preferably hot, through an emulsifier or dispersing machine to shear andsmear the softened polymer particles and further mix them into theresin/oil. Such apparatus, referred to herein sometimes asemulsifier/disperser, generates high shear, cutting and intensive mixingof the mixture at high speeds. The overall mixture is only present inthe dispersing device for a matter of minutes. The method may bepracticed on a batch basis or on a continuous basis.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of the invention is hereafter described withspecific reference being made to the drawings in which:

FIG. 1 is a schematic showing of the processing equipment used in abatch form of the subject method (external emulsifier).

FIG. 2 is a schematic showing of the processing equipment used in acontinuous form of the subject method (external emulsifier).

FIG. 3 is a schematic showing of the processing equipment in which thedisperser or emulsifier is included within the melting tank (internalemulsifier).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As already indicated, it is a primary aim of this invention, among otherthings, to reduce the process time significantly in the production ofblock polymer adhesives, particularly PSA's, and to reduce cost. It isalso an object to reduce temperature degradation of the polymer. This isaccomplished in the following preferred manner.

Referring to FIG. 1, an arrangement for practicing the method with an"external emulsifier" is shown as including a mixing vessel such as aholding tank, ribbon blender or the like, generally indicated at 10. Itis fitted with means for heating the contents thereof such as a steamjacket or hot oil jacket 12 and a mixer or agitation means such asblades 14 as are found in standard vertical mixers. A wide variety ofknown equipment may be used for tank 10 and elements 12 and 14, it onlybeing important that the equipment be capable of heating to temperaturesof about 220° F. to 300° F. and/or maintaining such temperatures tosoften the polymer, and mixing the softened polymer, resin and oilcomponents together. The resin and oil may be preheated prior tocharging to further reduce processing time. Ribbon blenders are readilyavailable from companies such as American Process Systems of Gurnee,Ill. 60031; Charles Ross & Son Company of Hauppauge, N.Y. 11788-0615;and Jaygo Incorporated of Mahwaugh, N.J. 07430.

An appropriate pump 16 is connected to vessel 10 to receive the liquidmelt contents thereof and pump them to an emulsifier/dispersing unit 18.Various types of equipment may be used for element 18, it beingimportant that it be capable of shearing and smearing the softenedpolymeric component of the melt and mixing it with the resin and oilcomponents thereof. By "shear and smear" it is meant that the polymer isnot only cut into small particles but it is squeezed and mechanicallydeformed at high speed between closely fitting surfaces in the device. Apresently preferred piece of equipment for this purpose is theDISPAX-REACTOR 3-Stage Dispersing Machine available from IKAMaschinenbau Janke & Kunkel GMBH & Co., KG. C/O IKA - Works, Cincinnati,Ohio 45240, which markets the DISPAX-REACTOR models andULTRA-TURRAX-INCLINE models of these machines. In a pilot operation a7.5 HP unit, model DR3/8/6, is satisfactory, operating at about 1gal/min for continuous batch method. For commercial production, a 50 HPunit operating at about 10 gal/min. would be useful for a continuousbatch method. Alternatively, a high speed mixer of the in-line typeavailable from Jaygo Incorporated and other suppliers may also be usedfor this purpose.

In practicing the preferred method of the invention, the resin and oilcomponents are charged to vessel 10 and heated to about 300° F. or theymay be preheated before charging. This temperature is not crucial butshould not be so high as to create any substantial degradation of theblock polymer component. It is only necessary that the temperature beadequate to soften the polymer particles. Typically polymers soften attemperatures of about 212° F.-300° F. The polymer component is added tothe hot charge in vessel 10. The polymer is preferably in a bead, crumbor other granulated or particulate form. The polymer will usually softenwithin a matter of minutes with such heating and with agitation byblades 14, after which pump 16 is activated and the hot liquid meltmixture is supplied to the unit 18 to shear and smear the polymer. Afterthis, the production of the adhesive is essentially completed. It thenflows to a holding tank and is thereafter packaged as desired. FIG. 1shows an arrangement for what may be thought of as a batch method.

The method of the invention may also be practiced on a continuous basisas shown by the arrangement of FIG. 2 which is also of the "externalemulsifier" type. In practicing such a form of the invention, thecomponents are metered into vessel 10 as indicated at 20, 22 and 24.Vessel 10 is sized to provide about 2 to 30 minutes hold time to insuresoftening of this polymer and the uniformity of the blend. The oil andresin or other constituents are stored in liquid form in feed tanks 20and 22. The liquids are added using positive displacement meter pumps(not shown) as are known in the art. The polymer particulate is addedusing a solid weight loss feeder 24 of the type also known in the art.The melt is stirred for hold times of about 10 minutes and pumped tounit 18 as before but on a continuous basis.

Referring now to FIG. 3, an arrangement referred to as the "internalemulsifier" is shown. In such an arrangement, the unit 18 is includedwithin tank 10 and merely causes by flowthrough the circulation of thecharge within vessel 10. Vessel 10 may be a Ross- type tank having atriple shaft mixer. The center shaft 30 is a sweep agitator that turnsslowly for batch turnover and wipes clean the vessel walls 10 forimproved heat transfer. A second shaft 32 is a Cowles-type mixer blade.The third shaft 34 is a mixer-emulsifier head. The mixer-emulsifier headhas a fitted outer slotted hub with a high speed inner hub rotor closelyfitted. The rotor pumps melt material into the hub and chops and smearsthe softened block polymer. The tolerances are very close to activelycut the polymer. The Charles Ross & Son Company markets several modelsof this type tank.

EXAMPLES

Various adhesive compositions were prepared using the method as follows.

Utilizing a system as shown in FIG. 3 with internal emulsifier, a Daymaxmixer with an Eastern Rotostat from EMI Incorporated of Clinton, Conn.06413-0912, (1 HP, 1750 rpm with 1/4" slotted head), oil, and resin weremelted at a temperature of about 330° F. This took about 15 minutes. TheDaymax agitator blades were turned on about 15 minutes and beads ofblock polymer were added to the melt. It was allowed to heat up andsoften for about 10 minutes and then the mixer/emulsifier unit wasactivated until the mixture appeared to be smooth--about 30 minutes toan hour.

The method was used to prepare adhesives such as:

    ______________________________________                                        PSA                                                                           ______________________________________                                        Segmented Styrene-butadiene block polymer                                                              14.5%                                                Linear styrene-isoprene block polymer                                                                  6.2%                                                 Zonstar 501 lite (tackifying resin)                                                                    58.6%                                                Mineral Oil              20.7%                                                                         100%                                                 ______________________________________                                        Non Tacky Block Polymer Adhesive                                              ______________________________________                                        Irganox 1076 (antioxidant)                                                                             0.3%                                                 Aromatic resin           15.0%                                                Polymerized resin acid   24.1%                                                Paraffin Wax 155F        23.0%                                                Linear styrene-butadiene block polymer                                                                 37.6%                                                                         100%                                                 ______________________________________                                    

Another procedure using a Ross Mixer as described above with internalemulsifier (See FIG. 3) was used as follows.

1. N₂ purge of vessel. Temperature set at 350° F.

2. Charge all oil. Begin heating and mixing.

3. Start sweep agitator.

4. Charge antioxidant.

5. Charge resin as fast as mixing will allow. Withhold 20% of resin (tobe added later for temperature control).

6. When batch temperature reached 300° F., emulsifier/dispersion unitstarted at high speed and block polymer charged.

7. Emulsified until smooth (1 hour or less).

8. Temperature set at 275° F.

9. Charge remaining resin (resin at ambient for pulling temperature down

10. Dump into drums.

Both pressure sensitive and non-tackifying adhesives may be prepared bythis method. Those adhesive compositions prepared passed all normalquality control specifications established for these adhesives asproduced by prior art methods. Several PSA compositions among otherswhich were produced according to the method of the invention andutilizing the Ross mixer as already described, for example, met productquality control specifications such as having viscosities at 300° F. of2,450 and 7,375 Centiposes, respectively and SAFT (shear adhesionfailure temperature) of 129° F.±1 and 145° F.±2. Some of these includedvarious KRATON block polymers.

While this invention may be embodied in many different forms, there areshown in the drawings and described in detail herein specific preferredembodiments of the invention. The present disclosure is anexemplification of the principles of the invention and is not intendedto limit the invention to the particular embodiments illustrated.

This completes the description of the preferred and alternateembodiments of the invention. Those skilled in the art may recognizeother equivalents to the specific embodiment described herein whichequivalents are intended to be encompassed by the claims attachedhereto.

What is claimed is:
 1. A method of preparing pressure sensitive adhesivecompositions comprising: forming a mixture comprised of oil, resin andblock polymer, subjecting the mixture to mixing in anemulsifier/disperser accompanied by shearing and smearing formechanically deforming and dispersing the block polymer throughout themixture at a mixing speed such as to provide a smooth mixture in aboutone hour or less.
 2. The method of claim 1 wherein the mixture is heatedbefore it is mixed in the emulsifier/disperser.
 3. The method of claim 1wherein the block polymer comprises polymerized styrene blocks andpolymerized butadiene blocks.
 4. The method according to claim 2 whereinthe temperature of the liquid mixture is in the range of about 220° F.to about 300° F.
 5. A method of preparing pressure sensitive adhesivecompositions comprising the steps:a) preparing a mixture comprised ofresin and oil in liquid form in a vessel; b) adding block polymer to themixture; c) heating the mixture to soften the polymer; d) passing themixture of resin, oil and block polymer through an emulsifier/dispersercapable of shearing and smearing the softened polymer at high speedthereby deforming it and dispersing it throughout the liquid withinabout an hour or less.
 6. The method of claim 5 including retaining themixture in the vessel at a heated temperature for a time sufficient tosoften the block polymer before it is passed through theemulsifier/disperser.
 7. The method of claim 5 wherein the heatingtemperature is in the range of about 220° F. to about 300° F.
 8. Themethod of claim 5 wherein the polymer comprises polymerized styreneblocks and polymerized butadiene blocks.
 9. The method of claim 5practiced on a continuous basis.
 10. The method of claim 5 practiced ona batch basis.
 11. The method of claim 5 wherein some of the totalamount of resin is withheld and added after emulsifying/dispersing theblock polymer and then the withheld resin is added.
 12. A method ofpreparing pressure sensitive adhesive compositions comprising: forming amixture comprised of oil, tackifying resin and block polymer, the blockpolymer comprising non-elastomeric blocks and elastomeric blocks,subjecting the mixture to mixing in an emulsifier/disperser accompaniedby shearing and smearing for mechanically deforming and dispersing theblock polymer throughout the mixture at a mixing speed such as toprovide a smooth mixture in about one hour or less.
 13. A method ofpreparing pressure sensitive adhesive compositions comprising thesteps:a) preparing a mixture comprised of tackifying resin and oil inliquid form in a vessel; b) adding block polymer to the mixture, theblock polymer comprising elastomeric blocks and non-elastomeric blocks;c) heating the mixture to soften the polymer; d) passing the mixture ofresin, oil and block polymer through an emulsifier/disperser capable ofshearing and smearing the softened polymer at high speed therebydeforming it and dispersing it throughout the liquid within about anhour or less.